installation, operation & maintenance instructions...

DOC: IOM_FNWG731_ver_09-2013 of 5

INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS

G731 GEAR OPERATOR

INTRODUCTION

This instruction manual includes installation, operation and maintenance information for the figure G731 gear operator. The figure G731 is particularly suited for the figure 7xx-series rubber seated valves, but can also be used on other butterfly, ball, or similar quarter-turn valves when properly sized and mated.

INSTALLATION

WARNING!To avoid personal injury to your self, fellow workers, or damage to property from release of process fluid, before installation to valves in service, ensure that the valve

a. Can be safely worked on while in serviceb. Can safely have current operator removedc. Can be fully stroked (operated) for setting purposes

If the valve can not be safely accessed in service, then the valve must be isolated, shut down, and system drained prior to installation. For best results, gears should be installed while the valves closing device (i.e. - disc, ball, plug, etc.) is visible.

In the following instructions, part numbers are indicated by parenthesis (x) and are referenced in the exploded view diagram and bill of materials at the back of this manual.

1. The figure G731 gear operator is designed for valves with clockwise-to-close functionality which is typical of most, but not all, quarter-turn valves. Verify that the gear’s rotation is compatible with the valve.

2. The figure G731 gear operator mounting is optimized for FNW figure 7xx-series rubber seated butterfly valves. Verify that stem and mounting hole dimensions are correct for a functional mechanical fit. Stem sleeves or mounting adaption may be required for dissimilar patterns. Note, the bore of the gear’s output drive goes through the entire gear. When using stem sleeves, it may be necessary to secure the sleeve from vertical movement to maintain mechanical connection.

3. Before installing the gear, inspect it and the valve for any damage that may have occurred and for any foreign matter that may have collected in shipping, storage, or operation. Inspect all mating surfaces, making sure they are free of dings and burrs that can obstruct smooth assembly.

4. Move the valve and gear to the near close (clockwise) position as shown. Note, the following diagrams show the gear with the cover (5) removed for illustration purposes only. Do not remove the cover for installation!

5. If needed, removed the indicator (13) To help line up the valve stem and gear bore.

6. Re-verify that the valve and gear are in the same near closed position. Carefully lower the gear over the valve stem and onto the valve’s mounting pad or mounting adaption.

7. Align the mounting holes of the gear operator with those on the valve mounting pad. If the holes are not aligned, adjust the gear position clockwise or counterclockwise to obtain proper alignment.

8. Secure the gear with bolts and lock washers (by others) and tighten.

9. If needed, reinstall the indicator (13) noting correct valve position. GEAR IN NEAR CLOSED (CW) POSITION



G731 GEAR OPERATOR

10. Remove the set screws (10) that are used to lock the stop screws (9) in place by turning them counter-clockwise with a hex wrench. In the same manner, back the stop screws (9) some to ensure full travel of the valve for setting purposes.

11. Use the hand wheel (16) to adjust the gear so that the valve is in the closed position. If the valve is installed, downstream witness, pressure gauges, or feel must be used. If the stop screw (9) is reached before full closure, back it out some more.

12. With the valve and gear in the closed position, use the hex wrench to adjust the close stop screw (9) in until it just makes contact with the worm gear (2) without moving the gear.

13. Return the set screw (10) over the close stop screw and tighten.



G731 GEAR OPERATOR

14. Move the gear to the full open position and repeat steps 11 and 12 to set the open stop. Note, if the valve is installed and the full open position can not be seen, starting from the full closed position, count the number of hand wheel turns that is equal to one-forth the gear ratio cast on the gear cover. For example, with a gear ratio of 50:1, turn the hand wheel 12-1/2 turns to approximate full open.

15. Adjust the position indicator (13) as needed by loosening the indicator screws (14) and turning the indicator. Due to differences in the many types of valves, the position indicator on the top of the gear operator may not line up exactly with the close and open marks. Correct setting of the gear should be determined by the position of the valves closing device (i.e. - disc, ball, plug, etc.), not the indicator.

OPERATION

WARNING!Do not use cheater bars, motor devices, or oversized hand wheels. The increased input torque could damage the gear operator or valve.

1. Rotation will continue until the gear contacts a travel stop. Do not attempt to excessively force the hand wheel beyond the stop as damage can occur to the gear or valve. If full closure is not achieved, review the setting of the travel stop listed in the installation section.

2. Clockwise hand wheel rotation will turn the gear clockwise (typically towards the closed position).3. Counter-clockwise hand wheel rotation will turn the gear counter-clockwise (typically towards the

open position).

MAINTENANCE

The figure G731 gear operator is not designed for rebuilding, nor is it economical to do so. Nevertheless, the gear should be included in routine inspection cycles at least annually.

At most, the gear should be checked for signs wear. Over time and/or with high frequency of use, internal parts can wear causing increased torque or loss of control. Verify functionality by operating the gear fully in both directions. Note if the stops (9) limit travel at the correct points and adjust if needed. Remove the indicator (13) and cover (5) to inspect the condition of the worm gear (2) and worm (3). If there is excessive wear, the gear operator should be replaced. Also verify that there is sufficient grease present on the worm gear and worm. Add additional mechanical grade grease as needed.

At minimum, verify functionality by operating the gear fully in both directions. Note if the stops (9) limit travel at the correct points and adjust if needed. Look for signs of lubricant loss due to oil separation of internal grease.

WARNING!1. Review safety checks prior to gear inspection as shown at the beginning of the installation section.2. Valves also wear over time or can be jammed with pipeline material. This can result in a seized

valve or dramatic increase in torque. It may be necessary to remove the gear from the valve in order to isolate if the issue is valve or gear operator related. Do not remove the gear operator until all safety concerns are met and the valve is decommissioned. Removal of the gear operator from an “in service” valve can result in the loss of valve position, control, and process media.



G731 GEAR OPERATOR

9. CW Stop Screw (Typically Closed Position)

9. CCW Stop Screw (Typically Open Position)

10. Set Screws

4. Worm Shaft

1. Body

3. Worm

6. Worm Pin

12. Gear O-ring

2. Worm Gear

11. Gasket

5. Cover

7. Cover Bolts

11. Gear O-ring

13. Indicator

14. Indicator Screws

8. Cover Washers

15. Shaft Seal

Ref. No. Description Material Qty Remarks

1 Body Cast IronASTM A126 Cl. B 1

2 Worm Gear Ductile IronASTM A536 65-45-12 1

3 Worm Steel 1

4 Worm Shaft Steel 1 Nickel Plated

5 Cover Cast IronASTM A126 Cl. B 1

6 Worm Pin Steel 1

7 Cover Bolt Steel 4

8 Cover Washer Steel 4

9 Stop Screw Steel 2

10 Set Screw Steel 2

11 Cover Gasket Rubber or Fiber Paper 1

12 Gear O-ring Rubber 2

13 Indicator Aluminum 1

14 Indicator Screws Steel 2

15 Shaft Seal Rubber 1

16 Hand Wheel Cast IronASTM A126 Cl. B 1 Not Shown

17 Hand Wheel Pin Steel 1 Not Shown

Standard Materials



G731 GEAR OPERATOR

WARRANTY

1. LIMITED WARRANTY: Subject to the limitations expressed herein, Seller warrants that products manufactured by Seller shall be free from defects in design, material and workmanship under normal use for a period of one (1) year from installation but in no case shall the warranty period extend longer than eighteen months from the date of sale. This warranty is void for any damage caused by misuse, abuse, neglect, acts of God, or improper installation. For the purpose of this section, “Normal Use” means in strict accordance with the installation, operation and maintenance manual. The warranty for all other products is provided by the original equipment manufacturer.

2. REMEDIES: Seller shall repair or replace, at its option, any non-conforming or otherwise defective product, upon receipt of notice from Buyer during the Manufacturer’s warranty period at no additional charge. SELLER HEREBY DISCLAIMS ALL OTHER EXPRESSED OR IMPLIED WARRANTIES, INCLUDING, WITHOUT LIMITATION, ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS OR FITNESS FOR A PARTICULAR PURPOSE.

3. LIMITATION OF LIABILITY: UNDER NO CIRCUMSTANCES SHALL EITHER PARTY BE LIABLE TO THE OTHER FOR INCIDENTAL, PUNITIVE, SPECIAL OR CONSEQUENTIAL DAMAGES OF ANY KIND. BUYER HEREBY ACKNOWLEDGES AND AGREES THAT UNDER NO CIRCUMSTANCES, AND IN NO EVENT, SHALL SELLER’S LIABILITY, IF ANY, EXCEED THE NET SALES PRICE OF THE DEFECTIVE PRODUCT(S) PURCHASED DURING THE PREVIOUS CONTRACT YEAR.

4. LABOR ALLOWANCE: Seller makes NO ADDITIONAL ALLOWANCE FOR THE LABOR OR EXPENSE OF REPAIRING OR REPLACING DEFECTIVE PRODUCTS OR WORKMANSHIP OR DAMAGE RESULTING FROM THE SAME.

5. RECOMMENDATIONS BY SELLER: Seller may assist Buyer in selection decisions by providing information regarding products that it manufacturers and those manufactured by others. However, Buyer acknowledges that Buyer ultimately chooses the product’s suitability for its particular use, as normally signified by the signature of Buyer’s technical representative. Any recommendations made by Seller concerning the use, design, application or operation of the products shall not be construed as representations or warranties, expressed or implied. Failure by Seller to make recommendations or give advice to Buyer shall not impose any liability upon Seller.

6. EXCUSED PERFORMANCE: Seller will make a good faith effort to complete delivery of the products as indicated by Seller in writing, but Seller assumes no responsibility or liability and will accept no back-charge for loss or damage due to delay or inability to deliver, caused by acts of God, war, labor difficulties, accidents, inability to obtain materials, delays of carriers, contractors or suppliers or any other causes of any kind whatever beyond the control of Seller. Under no circumstances shall Seller be liable for any special, consequential, incidental, or indirect damages, losses, or expense (whether or not based on negligence) arising directly or indirectly from delays or failure to give notice of delay.

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